Weld Cost Estimation Based on Cumulative Database

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ISSN(Online) : 2319-8753 ISSN (Print) : 2347-6710

International Journal of Innovative Research in Science,

Engineering and Technology

(An ISO 3297: 2007 Certified Organization)

Vol. 5, Issue 3, March 2016

Copyright to IJIRSET DOI:10.15680/IJIRSET.2016.0503220 4135

Weld Cost Estimation Based on Cumulative

Database

Priyesh Kakka[1] , Harsh Lodhavia[2], Bhavik Gandhi[3], Balkrushna Joshi[4]

B.E Student, Department Mechanical Engineering, Vidyavardhini’s college of engineering and Technology, Vasai (w),

India[1][2][3][4]

ABSTRACT: This paper presents a methodology by which estimation of cost in welding can be done using basic principles of welding and integrating it with software having a cumulative database which will facilitate the end user or a company to build the database and estimate the costs required for welding an assembly breaking it into parts and type of weld. The cost estimated would be made using scientific approach considering time required for each operation, consumables and cost associated with it also the method proposed reduces the manual input parameters as the database builds up minimizing errors. To Show the developed methods interest and the efficiency of the model a prototype has been tested ,the results obtained are compared to real time made by welding staff prove the rapidity and accuracy of this model .

KEYWORDS: Welding costs, Database, manual input parameters.

Nomenclature

I. INTRODUCTION

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and so an rough estimate is applied as we know that Costs studying is one of the basic imperatives of any decision making for enterprises working on request. In fact, the accuracy and the rapidity of cost estimation govern the transition to the effective order by the customer and help the enterprise to develop. At present, several data processing tools have been developed to evaluate the time and the manufacturing cost of mechanical parts. Bouaziz et al. [1] have proposed a system for the manufacturing cost of tools based on the semi-analytic approach. Shehab et al. [2] have developed a system which permits the modeling of production costs basing their theory on the integration of cost factors, of product developing activity and of the product geometry. The estimation is based upon connecting conception parameters and production parameters. Jung [3] developed an estimating system of a feature based cost for machined parts. Cost estimating for all features in a category is based on manufacturing activities. cost estimation for welding involves machining cost for edge preparation and welding cost which is tedious to calculate for each different assembly, in this paper a methodology is used to develop an software which will cumulatively accumulate company’s data reducing error and manual inputs over the period of time, initially various formula has been applied to calculate welding consumables cost , the basic indicator is time involved in various actions for various processes and mass of weld deposited .

II. COST AND TIME ESTIMATING MODEL

A. Weld Labor Cost The welding operation executing time is the arc time corrected thanks to the [6] Operator efficiency and to the coefficient of the positioning difficulty:

Where, SS (area of weld bead for butt weld) can be calculated as[4] :-

Fig.1.Butt Weld Area

SS = (((tan b x t) + g)xh)+g x t+2 x (tan b x t) xt) (2)

CsMO=tSCs (3)

B. Electrode Consumption Cost The electrode consumption cost is equal to the produce of the filling metal mass deposited and the electrode cost by mass unit. It is given by the following relation:

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C.Gas Consumption Cost The gas consumption cost is the produce of the consumed metal mass with the gas cost by

mass unit. It is expressed as follows:

D. Electric Energy Consumption For a welding operation the electric energy cost represents the consumed energy power used to deposit the volume of matter ma multiplied by the hourly cost. The electric energy consumption cost is given then by the following expression:

E. Weld Preparation Cost

CSMa= (SS-g x t) x Dm x Cms (7)

So the total cost is

CS = CSMO+CSEL+CSGA+ CSEE+ CSMa. (8)

III. DATA BASAE AND ANALOGY

Fig.2. Flow Methodology

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company to company like labor overhead costs, cost of electricity per unit etc has to be fed initially which can be stored and recalled whenever needed.

IV. APPLICATION

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International Journal of Innovative Research in Science,

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V. CONCLUSION

We have explained the concept and the basic principle peculiar to our approach of time and cost estimating in parts welding. The model by feature which we have developed is characterized by the weld geometric description and by the volume defining of the material added in welding. The formalization of the welding time is carried out by an analytic method of gas and electrode consumption according to the feature different geometric parameters and to the welding process. The cost estimating is assured by a parametric approach. The model includes all the stages of the welding process: preparation and weld. To automatize the cost generating process, it is necessary to integrate the modelling of knowledge, the modelling of the arguments for the generating of preparation and weld features allowing the identifications of the features cost as well as their suitable inductors. Extending the proposed approach to this direction is our interesting research perspective.

REFERENCES

1. Bouaziz Z, Younes JB, Zghal A Cost estimation system of dies manufacturing based on the complex machining features. Int JAdv Manuf Technol. DOI 10.1007/s00170-004-2179-3

2. Shebab E, Abdalla H (2002) An intelligent knowledgebased system for product cost modeling. Int J Adv Manuf Technol 19:49–65 3. Jung JY (2002) Manufacturing cost estimation for machined parts based on manufacturing features. J Intell Manuf 13:227–238 4. Gene Mathers,” http://www.twi-global.com/technical-knowledge/job-knowledge/calculating-weld-volume-and-weight-095/”TWI .

5. Hachicha, W., DEVELOPMENT OF A WELDING COST ESTIMATION MODEL BASED ON THE FEATURE CONCEPT. Advances in

Production Engineering & Management 2 (2007) 4, 149-162